Author: Scott McCarthy

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Case Study: 3 Metre Section of Corroded Steel Gas Pipe in CHP System Repair & Refurbishment

A heavily corroded steel pipe in a CHP system carrying natural gas undergoes repair with the Sylmasta Pipe Refurbishment System

Combined Liquid Metal and SylWrap HD repair combined heat and power system natural gas pipe

An industrial plant repair and refurbish a three metre section of steel pipe carrying natural gas in a combined heat and power system after water trapped between the line and an incorrectly installed PVC tape caused heavy corrosion.

Case Study Data

Site
Industrial Plant
Location
Puerto Rico
Repair Type
Pipe refurbishment
Defect
Three metre section of corroded 100mm steel pipe in CHP system

Products Used

Liquid Metal Epoxy Coating
Brush applied coating which cures to form an ultra-smooth, hard wearing, metallic surface over pipes and structures

SylWrap HD Pipe Repair Bandage
Composite repair wrap with a water activated resin which sets rock hard to encompass pipes with an impact resistant outer sleeve

Case Study PDF

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Case Study Details

The pipeline was 100mm in diameter and ran for 365 metres through the plant, carrying natural gas produced by a combined heat and power system. It was hung on a series of U-shaped supports welded to I-beams suspended from the roof of the building.

When originally installed, the pipe had been wrapped with a protective PVC tape. Unfortunately, incorrect application of the tape had left a three metre section where it was possible for water and condensation to become trapped between the tape and the line.

Removal of the yellow PVC tape revealed very heavy corrosion to the steel pipe

This had led to heavy corrosion, which was particularly prevalent at the bottom of the pipe and the area where the section in question rested on its U-shaped support. The weakened three metres of the natural gas pipe now required strengthening and repair before the steel became breached.

Th pipe was cleaned of paint and grime before repair of the corroded surface

The plant decided to use the Sylmasta Pipe Refurbishment System to bring the damaged section of the line back up to specification, by reinforcing the metalwork and giving the pipe greater protection against future corrosion.

First, the U-Shaped support was cut away from the I-beam to enable better access to the corroded area. The PVC tape was removed and rust, grime and paint ground off. Alcoholic cloths were then used to remove any remaining residue from the grinding process.

Liquid Metal applied to repair a natural gas pipe suffering from heavy exterior corrosion
Liquid Metal was brush applied across the three metres of the pipe suffering from corrosion

To repair the damage and restore the pipe exterior, the three metre section was coated in Liquid Metal Epoxy Coating. Liquid Metal is brush applied and cures to form a smooth, metallic, hard-wearing outer surface which acts as a shield against external corrosion and chemical attack.

The 90 minute gel time of Liquid Metal allowed significant amounts of epoxy to be mixed and painted on without the threat of premature curing. A SylWrap HD Pipe Repair Bandage was then wrapped around the area of the line which had contact with the U-shaped support.

SylWrap HD Pipe Repair Bandage applied to a heavily corroded steel natural gas pipe
SylWrap HD was wrapped around the area of the pipe which came into contact with the U-shaped support, which was to be welded back in place to the I-beam above

SylWrap HD is a composite repair wrap with a water-activated resin. It was applied whilst the Liquid Metal remained tacky and cured within minutes to form a rock-hard, impact resistant outer shell around the pipe. This further increased the thickness of the weakened section and provided an additional layer of protection.

A second layer of Liquid Metal was applied across the three metre section, including over the SylWrap HD. Although an additional coating on top of the composite bandage is not a required step of the Sylmasta Pipe Refurbishment System, the plant wanted to make the line look aesthetically pleasing with a final metallic finish.

A second Liquid Metal coating was applied over the SylWrap, the U-support welded back in place and the pipe fixed to it via a support clamp

Once the pipe had been refurbished, the removed U-shaped support was welded back to the I-beam. The line was then fixed to the U-shape via a new pipe support clamp fitted to prevent movement caused by vibration. The clamp was also coated in Liquid Metal.

Refurbishing the pipe was carried out with no impact to operations at the plant. It prevented an expensive and disruptive future repair or replacement being needed when corrosion eventually ate through the line.

The ultra smooth finish provided by Liquid Metal compared to the pitting caused by corrosion

The plant were very happy with the outcome and how easy their maintenance team found the application. They are now intending to use Liquid Metal to extend the lifespan of other pipes and structures at both this facility and across other sites.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Leaking Welded Saddle Joint Repair on 150mm Steel Pipe at Pumping House

A leaking saddle joint welded on a 150mm steel pipe undergoes repair after being found to be leaking from both ends

Saddle up for a complex repair – sealing a leaking welded saddle joint with a 20mm step using Wrap & Seal Pipe Burst Tape

A 150mm steel pipe connected to a pumping house in Malaysia which was leaking from both ends of a welded saddle joint is sealed in a successful repair built up and over a 20mm step between the line and the joint.

Case Study Data

Site
Pumping house
Location
Malaysia
Repair Type
Live leak repair
Defect
Leaking saddle joint on a 150mm steel pipe with a 20mm step

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which sealed up and over the leaking saddle joint weld

Case Study PDF

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Case Study Details

The 150mm steel pipe ran water out of the pumping house. The saddle joint had been welded in place to reinforce a capped tee and sat approximately 20mm higher than the original line. One end of the joint was suffering from heavy corrosion.

Water had been found seeping from both ends of the joint, leaving the pipe surface noticeably wet and the ground beneath the pipe sodden. The pipe could not be isolated or replaced because this would involve shutting down the pumping station.

Several repair attempts had failed, including a clamp
A 150mm steel pipe with a heavily corroded saddle joint prior to undergoing leak repair
One end of the saddle joint was suffering from heavy corrosion whilst water was seeping from both

Several repair attempts had been made using different methods by the water company operating the facility, including the use of a clamp and epoxy putty, but none had been successful. The pipe had therefore been left to leak.

Whilst on a visit to Malaysia, a technician from Sylmasta was asked to accompany a engineering team to inspect the pipe and see if a solution could be formulated. They recommended using Wrap & Seal Pipe Burst Tape to start a repair on the original steel pipe and build it up and over the weld, encompassing and sealing either end of the saddle joint.

The pipe was cleaned and prepared before repair

First, an angle grinder was used to sand down the pipe, clean it of loose material and remove corrosion. A first Wrap & Seal Tape was then applied directly next to the step. Wrap & Seal is made from self-amalgamating silicone and stretches by three times its length, fusing together to form a solid rubber band.

Diagram explaining how to repair a leaking saddle joint weld with a step using Wrap & Seal Pipe Burst Tape
Wrap & Seal application started on the pipe next to the saddle, was built up until level with the step and then continued across onto the joint

With each rotation, the Tape moved closer to being level with the top of the saddle joint. The application continued until enough Wrap & Seal had been applied to bridge the 20mm step between the pipe and the saddle.

Once this had been achieved, Wrap & Seal was applied 50mm across the saddle to achieve a good connection. It was then returned to directly over the edge of the joint.

Once Tape had been built up and over the saddle, wrapping continued immediately over the leak area
Wrap & Seal Pipe Burst Tape applied to a leaking saddle joint in a successful repair despite a 50mm step being present
The finished repair with both ends of the saddle joint sealed

Here, a ridge was created directly over the leak area to increase the pressure resistance of the repair. It was estimated that three Wrap & Seal Tapes needed to be used to seal one end, after which the process was repeated at the other end of the saddle joint.

Because the welded saddle joint had been seeping water slowly, the only way to check whether the application had been effective was to inspect several days later. When the pipe surface was found to be dry, the repair was deemed a success.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Burst Copper Pipe Repair in Portable Horse & Dog Shower Unit

A copper pipe burst during freezing winter weather undergoes repair with a SylWrap Standard Pipe Repair Kit

Replacement? Hold your horses – the repair of a burst copper pipe which had a horse shower running again in no time

When freezing winter weather led a copper pipe in a portable horse and dog shower to burst, it required a quick and simple repair method capable of being effective inside the cramped space of the unit.

Case Study Data

Site
Portable horse and dog shower
Location
United Kingdom
Repair Type
Leak repair
Defect
Split in copper pipe caused by freezing temperatures

Products Used

Superfast Copper Epoxy Putty Stick
Fast-working epoxy putty pushed into the crack in the copper pipe to seal it

SylWrap HD Pipe Repair Bandage
Composite repair wrap applied over Superfast Copper to reinforce the initial repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

Showerking are a Sussex-based supplier of portable hot shower units designed for horses and dogs. Units are typically stored in unheated outbuildings. Although designed to handle winter weather, copper pipe in the unit which has not been fully drained becomes prone to bursting during periods of exceptionally cold weather.

When temperatures in the United Kingdom dropped as low as -15°C, several Showerking owners reported burst pipes which rendered their units unusable. If they turned the shower on, water would spray out of the large crack created in the copper pipe.

Freezing temperatures had created a split in the copper pipe

Fortunately, Showerking had already contacted Sylmasta about the possibilities of pipe repair for horse showers. The SylWrap Standard Pipe Repair Kit provided the most suitable method as units would be turned off in the event of leaks or bursts, meaning no pressure to the pipe.

It had been established that the smallest Standard Pipe Repair Kit (SYL-106-NP) was ideal for application because of both the cramped space inside the unit and the difficult shape of the pipework. There were many bends which were unrepairable with a clamp.

Through the relationship between Showerking and Sylmasta, users whose horse showers had suffered burst pipes were directed to the exact product they needed to fix the problem, and had the straightforward repair process explained to them.

Superfast Copper Epoxy Putty used to repair a burst in a horse shower copper pipe caused by freezing temperatures
Superfast Copper Epoxy Putty was used to cover the split

Loose material was removed from the burst copper pipe before repair. Superfast Copper Epoxy Putty Stick was then used to seal the crack. Enough putty to cover the crack was cut from the stick and kneaded by hand until it turned a uniform colour.

Whilst soft, the putty was pushed onto the pipe, encompassing the entire crack. This completed the first stage of the repair. The second stage involved applying a SylWrap HD Pipe Repair Bandage over the Superfast Copper.

A burst copper pipe in a portable horse shower unit repaired and reinforced with SylWrap HD Pipe Repair Bandage
The repair was finished with reinforcement via a SylWrap HD Pipe Repair Bandage

SylWrap HD is a composite repair wrap with a water-activated resin which sets rock hard. The bandage was wrapped and smoothed around the pipe as the Superfast Copper began to harden, forcing the putty into the crack to create a permanent, watertight seal.

Within five minutes of SylWrap HD being applied, the bandage had cured to form a rock hard shell reinforcing the pipe, and which also offered protection from expansion in the future. The completed repair was resistant to 30bar, making it more than capable of holding the pressure the horse shower unit operated at.

The repair took less than 30 minutes from start to finish and the SYL-106-NP Standard Pipe Repair Kit cost under £25 including delivery, returning the £180 Showerking unit to service the same day.

For more information about portable horse and dog showers, please see the Showerking website.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Seawater Storage Tank Floor Repair at Gas Processing Plant in Saudi Arabia

Sylmasta AB Original Epoxy Putty used to repair cracks in the floor of a seawater storage tank

Corrosion could have floored this seawater storage tank – until a repair involving Sylmasta AB Original Epoxy Putty

The floor of a seawater storage tank at a gas processing plant in Saudi Arabia undergoes repair after gaps appeared between rubber sheeting, leaving the concrete which coated the bottom of the tank unprotected and exposed.

Case Study Data

Site
Gas processing plant
Location
Saudi Arabia
Repair Type
Floor repair
Defect
Gaps between rubber sheeting leaving concrete tank floor exposed

Products Used

Sylmasta AB Original Epoxy Putty
Waterproof, hard-wearing epoxy putty with a longer work time used to permanently fill gaps and cracks

Case Study PDF

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Case Study Details

The plant collected gasses produced during the extraction of crude oil – such as propane, butane, methane and ethane – and converted them into a number of different chemicals exported worldwide for industrial and agricultural use.

Seawater was extracted from the Persian Gulf and stored in vast metal tanks for use in cooling and other processes on site. The interior of each tank was concrete coated and then lined with rubber matting for protection against corrosion.

Problems with one tank led to it being drained for inspection. This revealed sections of the rubber matting on the floor of the tank had become loosened, lifted and completely broken apart in some places, leaving the concrete lining exposed.

The rubber matting of the tank floor had become damaged, exposing the concrete coating below

There was a risk that this exposure could lead to seawater finding a way through the concrete and coming into contact with the metal frame beneath. This would put the tank in danger of serious and irreparable damaged caused by corrosion. All gaps in the rubber sheeting therefore had to be sealed before the tank could go back into service.

The engineering team carrying out the seawater tank repair decided to use Sylmasta AB Original Epoxy Putty for the application. AB Original is ceramic-filled, making it stronger and harder wearing than other epoxy putties. It is fully waterproof, adheres to wet surfaces and its high chemical and corrosion resistance mean it is often used as a sacrificial layer.

Sylmasta AB Original Epoxy Putty is pushed into cracks to repair a seawater storage tank floor
Sylmasta AB Original Epoxy Putty applied to cracks in the floor of a seawater storage tank to make a repair
Cracks in the coating of a seawater storage tank after repair with Sylmasta AB Original Epoxy Putty
AB Original was used to fill all gaps for the protection of the exposed concrete

AB Original was mixed by hand. Whilst soft enough to shape and manipulate, it was forced into the gaps and cracks between the rubber sheeting and smoothed off with water and a hand tool.

The two hour work time of AB Original allowed large amounts of putty to be mixed and applied without the threat of premature curing. Once hardened, the putty permanently filled every gap with a waterproof material, protecting the concrete lining from seawater exposure.

The repair was completed by coating fibreglass sheets with an epoxy to form a new protective surface over the damaged rubber matting

After the application of AB Original, fibreglass sheets were layered over the rubber matting and coated with an epoxy resin. This created a new reinforced floor surface over the damaged rubber, offering yet another layer between seawater and the metal frame of the tank.

The plant could then put the tank back into operation safe in the knowledge that the metalwork was now far better protected by a combination of concrete, AB Original, rubber matting and an epoxy composite repair.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Live Leak Repair of 150mm Cement Coated Steel Pipe on Water Network in Mexico

An underground cement coated steel pipe leaking through an 80mm long split is repaired using a SylWrap Pipe Repair Contractor Case

Contractor Case calling – the cement coated steel pipe repair carried out by engineers in Mexico equipped for every leak

An underground cement coated steel pipe on a water network in Mexico undergoes a live leak repair after excavation followed by the removal of the outer coating revealed a 80mm long split in the line.

Case Study Data

Site
Underground water network
Location
Mexico
Repair Type
Live leak pipe repair
Defect
80mm split in a cement coated steel pipe carrying potable water

Products Used

Wrap & Seal Pipe Burst Tape
Self-amalgamating silicone repair tape which seals high pressure live leaks by fusing together to form a solid rubber band

SylWrap HD Pipe Repair Bandage
Water-activated composite wrap which sets rock hard, providing an effective replacement for the removed cement coating

SylWrap Pipe Repair Contractor Case
Products were supplied as part of a Contractor Case, capable of making up to six live leak repairs

Case Study PDF

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Case Study Details

A potential leak was identified on a section of the water supply network running beneath a street. Excavation took place and revealed a cement coated steel pipe suffering from a crack around 15mm wide across the diameter of its outer coating.

There was no sign that any water had escaped through this crack. To inspect the condition of the pipe inside, engineers removed the cement using a hammer and chisel. As the coating was chipped away, water began spraying out from a 80mm long split in the steel pipe.

A cement coated steel pipe suffering from a 15mm crack before undergoing repair with a SylWrap Pipe Repair Contractor Case
A 15mm wide crack had appeared in the cement coating around the steel pipe
As the coating was removed, water began spraying out from a split in the steel pipe

By the time the cement coating had been fully removed from around the leak area, enough water had escaped into the excavation hole to half-submerge the pipe. There was no means of isolating this section of the network and so the only option was to make a live leak repair.

The specialist company involved in the identification of the leak and excavation of the pipe equip all their engineering teams with SylWrap Pipe Repair Contractor Cases, meaning everything needed to seal the pipe was already on-site.

Contractor Cases contain enough WRAS approved products to make up to six permanent live leak repairs to pipes of all diameters and materials. WRAS approval was necessary for this application because the pipe carried potable water.

A split discovered in cement coated steel pipe before undergoing repair with a SylWrap Pipe Repair Contractor Case
Engineers were equipped with a SylWrap Pipe Repair Contractor Case which they used to seal the split once the cement coating had been fully removed

A bucket was used to remove enough water from the hole to enable the repair to take place. Wrap & Seal Pipe Burst Tape was used to seal the leak in the line, with several Tapes applied to cover the entire length of the split in the steel.

Wrap & Seal is made from self-amalgamating silicone. When stretched and wrapped, it fuses to itself to form a solid rubber band. Multiple Tapes can be applied over each other to build pressure resistance up to 30bar. For this repair, the requirement was around 3bar.

Enough Wrap & Seal Tapes were applied until the leak had been fully arrested. A SylWrap HD Pipe Repair Bandage was then wrapped over the top for the purpose of reinforcing and protecting the initial repair.

The completed repair of a leaking cement coated steel pipe in Mexico using a SylWrap Pipe Repair Contractor Case
The pipe was successfully sealed in under an hour

SylWrap HD is a composite wrap with a water-activated resin. After being wrapped and smoothed around the pipe, the bandage set rock hard in minutes. The impact resistant sleeve formed by SylWrap provided an effective replacement for the removed cement coating.

The application was completed in under an hour. Having all the products required to repair the cement coated pipe ready and available via the Contractor Case made a significant difference to response time and how quickly the leak could be sealed, reducing the amount of water lost and disruption to supplies.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Power Station Repair Extensive Damage to Alloy 20 Pump Lid Caused by Impeller

Ceramic Brushable Green Epoxy Coating is used to repair a badly damaged Alloy 20 pump lid at a power station water treatment plant

Keeping a lid on the cost of repair for a power station treatment plant pump in Puerto Rico

A power station in Puerto Rico repair a treatment plant pump lid made from Alloy 20 which would have cost $4000 to replace after it suffered extensive damage when an impeller fell out of place.

Case Study Data

Site
Power station treatment plant
Location
Puerto Rico
Repair Type
Damage repair
Defect
Gouged and scratched Alloy 20 pump lid

Products Used

Ceramic Brushable Green
Brushable epoxy coating used to repair surface damage and offer greater protection of the Alloy 20 pump lid

Case Study PDF

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Case Study Data

The pump lid came from a mud pool at the power station treatment plant. It was 500mm in diameter and made from Alloy 20 (nickel-chromium-molybdenum stainless steel) for its high chemical and corrosion resistance.

Extensive damage had been caused when an impeller blade came out of place and fell directly onto the lid, leaving numerous scratches and several very deep gouges across the surface.

A replacement lid would have cost $4000 and required shipping to Puerto Rico, potentially leaving the pump out of service for a significant amount of time and causing disruption to operations.

The power station instead used Ceramic Brushable Green Epoxy Coating to repair the pump lid. Ceramic Brushable is reinforced with silicone carbide, giving it a toughened, ultra-smooth finish.

It is painted onto surfaces which have suffered heavy surface damage or been weakened by corrosion and abrasion, restoring their strength and protecting the original part from further deterioration.

A pump lid made from Alloy 20 undergoes repair at a power station treatment plant after being damaged by an impeller
The pump lid having been fully repaired by Ceramic Brushable Green Epoxy Coating

The lid was removed from the pump. Part A and Part B of Ceramic Brushable Green were mixed and then applied via brush. The first few coatings were used to repair the damage by filling in the gouges and scratches, found mostly in the centre of the lid.

This was followed by additional layers being added across the entire 500mm area, creating a new reinforced surface over the original Alloy 20 to offer protection to the lid.

Once the final coating of Ceramic Brushable Green had begun to harden, the lid was turned on a lathe to finish it. The two colour tones on the complete repair show where the lid is angled towards the edge.

After a full cure had been achieved, the lid was fitted back in place and the water treatment plant could return to full service. The power station were extremely pleased with the application as it prevented a costly replacement which would have resulted in downtime at the site.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Trenchless Pipe Installation Protection of 150mm Steel Natural Gas Pipeline

SylShield is used to offer protection to welds and joins in a steel natural gas pipe to undergoe trenchless installation in Czech Republic

Czech mate – SylShield protection enables the trenchless installation of a natural gas pipeline in south east Czechia

In its first deployment in the field, SylShield was used for the protection of welded joints on a 150mm diameter steel pipeline carrying natural gas when it was rerouted beneath a road and river via horizontal directional drilling, a form of trenchless pipe installation.

Case Study Data

Site
Natural gas pipeline
Location
Czechia
Repair Type
Pipe and weld protection
Application
Protecting 150mm steel pipeline undergoing trenchless installation via horizontal directional drilling

Products Used

SylShield Pipe & Weld Protection Wrap
Composite repair wrap three times thicker than standard SylWrap HD for protecting pipes during trenchless installation

Case Study PDF

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Case Study Details

Horizontal directional drilling involves connecting together sections of a pipeline above ground via welding or a similar process, digging a borehole and pulling the completed line through to install it.

This removes the need to dig huge and disruptive trenches across vast swathes of land. It also allows pipes to be installed beneath roads, rivers, seas and other areas which would otherwise be challenging to pass. In some cases, pipes many kilometres in length are dragged through the ground and installed using horizontal direction drilling.

The pipeline arrived on site in numerous separate sections before behind welded together

The high-pressure natural gas pipeline in the south of Czechia was being rerouted to improve energy security for the country. It was to pass under a local road and stream, meaning that horizontal directional drilling was the most suitable form of trenchless installation.

Pipes undergoing trenchless installation are given protection against the potential damage caused by dragging them underground. The 150mm diameter steel pipe being used in this application was coated in both epoxy and a 3mm thick fibreglass composite.

A 150mm natural gas pipeline to undergo trenchless pipe installation prior to having SylShield protection wrap applied
Joins on the pipe (black section) where welding had taken place could not be protected by epoxy or fibreglass, as the rest of the steel was

Joins on the pipe are more challenging to protect. The points at which sections are welded together cannot be covered with epoxy, fibreglass or any other type of factory applied protection. This is where SylShield came in.

The company installing the line were a long-time client of Sylmasta. They got in contact to ask if there was a potential solution for protecting the joints in the pipe, in addition to the heat shrink sleeves used as standard.

SylShield was activated with water and then applied over the joins in the pipe

SylShield Pipe & Weld Protection Wrap is the toughest, most robust composite wrap in the SylWrap range three times the thickness of a standard SylWrap HD Pipe Repair Bandage. It has been specifically designed for the protection of pipelines during trenchless pipe installation.

Working to a tight deadline, Sylmasta were able to produce the required number of SylShield wraps at their factory in England on the Thursday and deliver them to Czechia. The installation team collected the products from a DHL depot on Monday morning and set to work immediately.

SylShield was smoothed with water, curing to form an ultra hard shell protecting the welds in the pipe

Each welded joint and heat shrink sleeve was overwrapped with SylShield. The resin was activated with water and SylShield wrapped and smoothed around the pipe. Within minutes, it cured to form a rock-hard sleeve encompassing the joint to protect it from the rigours of horizontal directional drilling.

As each section was wrapped with SylShield, shrink wrap was applied over the top to secure the composite against the pipe and improve lamination. The shrink wrap was then spiked, ensuring that the carbon dioxide released during the curing of SylShield could escape rather than becoming trapped.

SylShield used for the protection of a natural gas line ahead of trenchless pipe installation
A natural gas line given protection before trenchless pipe installation with SylShield Pipe & Weld Protection Wrap
Once the joins in the line had been protected, the pipe was ready to be pulled through the ground and installed via horizontal directional drilling

By Monday evening, the entire line had been welded together, protected with SylShield and pulled through the borehole under the road and stream to complete the trenchless installation. Sylmasta had played a small but important part improving natural gas supplies to Czechia.

Afterwards, the team leader responsible for the project emailed to say: “The installation was a success and we particularly appreciated the timely delivery of the SylShield wraps. Big thanks to Sylmasta for meeting the tight deadline, which even we thought would be unrealistic.”

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Repair of Leaking Stainless Steel Pipe Inside Farm Biodigester Tank

A stainless steel pipe in a biodigester tank at a pig farm undergoes repair using a SylWrap Universal Pipe Repair Kit

Rescuing a pig’s ear of a repair – SylWrap seals a leaking pipe in a farm biodigester tank after patch welding failed

A leaking stainless steel heating pipe inside a biodigester tank at a pig farm undergoes repair after an initial attempt to arrest the damage via patch welding was found to have failed.

Case Study Data

Site
Pig farm
Location
United Kingdom
Repair Type
Leak Repair
Defect
Damaged stainless steel pipe in biodigester tank

Products Used

Wrap & Seal Pipe Burst Tape
Repair tape with high pressure and temperature resistance to seal the leak

SylWrap HD Pipe Repair Bandage
Provided an impact-resistant layer to protect against possible future damage

SylWrap Universal Pipe Repair Kit
The products were supplied to the farm in a SylWrap Universal Pipe Repair Kit

Case Study PDF

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Case Study Details

Biodigester systems are installed on farms for the purpose of turning waste into fertiliser and gas. The process involves organic material such as plant matter and animal manure being diluted with water and mixed in an airtight tank. Microorganisms present in the waste ferment the mix, creating a liquid called digestate.

During fermentation, the bacteria responsible for decomposition produce methane. Also known as biogas, this methane is captured and used to help power the farm. Digestate meanwhile is either kept in its liquid form and sprayed back onto the farm as fertiliser, or it can be dried out to a solid material which is used for animal bedding.

The biodigester system at the pig farm consisted of a wide circular tank 20 metres in diameter and around five metres tall. Inside the tank were a number of stainless steel heating pipes which warmed the digestate to aid fermentation. The digestate itself was mixed by a large propeller blade attached to a metal pillar.

The propeller mixer blade and metal pillar had caused damage to a steel pipe behind

Over time, the propeller mixer had pushed the metal pillar backwards to the point where it came into contact with one of the heating pipes. This in turn led to a breach of the steel and a leak developing.

The farm were alerted to the problem through a noticeable drop off in the efficiency of the biodigester. They accessed the inside of the tank, discovered the damage and attempted to try and seal the pipe via patch welding.

Patch welding failed to seal the leak with numerous pinhole leaks appearing through the weld, after which it was ground down for a SylWrap repair

Not long after the repair and again the biodigester began underperforming. A second inspection revealed that the patch welding had failed, with water sprouting out of numerous pinhole leaks through the weld.

The farm opted for a SylWrap Universal Pipe Repair Kit for their second repair attempt. The pipe was cleaned and the patch weld ground down prior to Wrap & Seal Pipe Burst Tape being applied as the first stage of the SylWrap repair.

Wrap & Seal Pipe Burst Tape used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
Wrap & Seal Pipe Burst Tape applied along a 600mm long repair area

There being multiple leak areas across a 600mm area of pipe made it easier to wrap along the length of the line using Wrap & Seal than trying to encapsulate or plug each individual hole with Superfast Epoxy Putty.

When applied to the pipe, Wrap & Seal amalgamated to form a solid rubber band over every pinhole leak present. The tape was easily capable of withstanding both the pressure and temperature which the heating pipe operated at.

SylWrap HD Pipe Repair Bandage used to seal a leaking stainless steel heating pipe in a biodigester tank and a pig farm
SylWrap HD provided an impact resistant sleeve to protect the pipe from future contact with the pillar

To reinforce and protect the repair should the mixer blade and pillar come into contact with the pipe again in future, a SylWrap HD Pipe Repair Bandage was applied over the top of the Wrap & Seal.

The resin within SylWrap HD was activated with water and the bandage wrapped and smoothed around the pipe. It cured in minutes, encompassing the entire repair with a rock hard sleeve capable of protecting the pipe from impact by the pillar.

Applying Wrap & Seal and SylWrap HD took less than one hour. The biodigester tank was put back into service the following day and with no issues regarding the efficiency or performance of the system noticed, the pipe repair was deemed a success.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Reinforced Welded Corners in Chromic Acid Tank Sealed Using SylWrap HD

A chromic acid tank at a factory in Argentina undergoes repair to heavily corroded corners using SylWrap HD Pipe Repair Bandage

Preventing a chromic acid attack – SylWrap HD seals welded corners in a corroded tank repair

After new corners were welded in place during the repair and reinforcement of a badly corroded chromic acid tank at a factory in Argentina, SylWrap HD provided sealing security against any leaks in the welding.

Case Study Data

Site
Chroming factory
Location
Argentina
Repair Type
Tank repair
Defect
Reinforcement and sealing of corroded tank corners

Products Used

SylWrap HD Pipe Repair Bandage
Composite wrap used to encompass parts and structures which sets rock-hard for ultimate protection

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Case Study Details

The iron tank was at a chroming factory in Argentina. It held chromic acid and was used during the re-chroming process of piston parts for oil extraction pumps. It was 10 metres long, 1.5 deep and 1.5 metres wide.

After a long time in service, the tank was suffering from corrosion. The damage was particularly heavy in the corners. The factory decided to repair the chromic acid tank, which involved installing welded reinforcements to each inside corner.

Not wanting to risk the possibility of there being leaks in the welding which could cause a future escape of chromic acid, the factory used SylWrap HD Pipe Repair Bandage to provide additional sealing security to the corners of the tank.

New metal corners were welded to reinforce the corners of the tank. These were then covered in SylWrap HD

The normal method of application for SylWrap HD is to activate the resin, then wrap around the pipe or structure requiring repair whilst the bandage cures to form a rock hard material.

Wrapping was obviously not possible to the inside of the tank. Instead, the factory unwound their SylWrap HD and cut it into patches, making sure not to contaminate the bandage with dirt or grime.

These patches of SylWrap HD were then activated and smoothed as tightly as possible up the entire 1.5 metre length of the welded reinforcement, creating a watertight seal between the weld and the existing frame of the tank.

The corner of a chromic acid tank having undergone repair and reinforcement using SylWrap HD Pipe Repair Bandage
Complete repair with patches of SylWrap HD encompassing the welded corner, sealing any potential holes or cracks

SylWrap HD was applied to all four corners of the tank in this way. Within 10 minutes of application, it had completely set to encompass each welded corner and cover any gaps or holes which may have otherwise been left exposed.

The final stage of the tank repair saw an acid-resistant PVC covering added. Whilst SylWrap HD offers good resistance against chemicals including sulphuric acid (which is a stronger concentration than chromic acid), this additional step was taken with the aim of further protecting the entire tank from future corrosion and attack.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com

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Case Study: Boat Owner Repairs Pinhole Leak in Rubber Hose Connected to Engine

A rubber hose connecting to a boat engine undergoes repair using a SylWrap Standard Pipe Repair Kit

Plain sailing – a rubber hose connected to a boat engine undergoes repair after developing a pinhole leak

A boat owner keeps their vessel afloat by making a repair to a pinhole leak on a difficult to access section of hardened rubber hose which played an important role in the cooling of the engine.

Case Study Data

Site
Boat
Location
United Kingdom
Repair Type
No pressure pipe repair
Defect
Pinhole leak in rubber hose connected to boat engine

Products Used

Superfast Steel Epoxy Putty Stick
Fast working steel epoxy putty used to seal the pinhole leak in the hose

SylWrap HD Pipe Repair Bandage
Composite wrap applied over the sealed pinhole leak for reinforcing the repair

SylWrap Standard Pipe Repair Kit
Superfast Epoxy and SylWrap HD are supplied together in the Standard Pipe Repair Kit

Case Study PDF

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Case Study Details

The hose was connected to the engine, carrying water as part of the cooling process. Once the pinhole leak had developed, water was able to spray out at high pressure whenever the engine was in service. This was dangerous and unsustainable.

Repairing the leak was made challenging by the pinhole being located on a bend in the rubber hose. The hose itself was in a confined space below deck, surrounded by other pipes and engine components. A pipe repair clamp could not be fitted because of the constraints.

The hose was in a confined space making a repair difficult

The boat owner contacted Sylmasta seeking a versatile repair method capable of sealing the leak despite the difficulties in accessing the hose. A SylWrap Standard Pipe Repair Kit containing all the products needed to repair a pipe when pressure can be turned off was recommended for the application.

First, the pinhole was sealed using Superfast Steel Epoxy Putty. The putty was kneaded by hand and whilst soft, applied over the pinhole leak. It easily adhered to the rubber. After 5 minutes when the putty had started to harden, it was overwrapped using a SylWrap HD Pipe Repair Bandage.

SylWrap HD is a composite wrap with a water-activated resin, which sets rock hard in five minutes. As the Bandage was wrapped and smoothed around the hose, it forced the Superfast Steel as it cured further into the pinhole, completely sealing the leak. Once SylWrap HD had set, it formed an impact resistant sleeve to increase the repair’s effectiveness.

Superfast Steel Epoxy Putty used to repair a rubber hose in a boat engine system suffering with a pinhole leak
A rubber hose connecting to a boat engine wrapped with SylWrap HD Pipe Repair Bandage
Superfast Steel was used to seal the pinhole. The repair was reinforced with SylWrap HD Pipe Repair Bandage

When used together, Superfast Steel and SylWrap HD create a repair with pressure resistance up to 30 bar and temperature resistance to 200ºC. When the boat engine was started, no water was escaping from the hose. The vessel could return to the sea.

Completing the boat pipe repair took under 30 minutes and cost less than £25, including delivering of the SylWrap Kit. This represented a significant cost saving compared to quotes offered by specialist marine engineering contractors to fix or replace the hose.

If you have an application you would like to enquire about, then please get in touch

Call: +44 (0)1444 831 459
Email: sales@sylmasta.com