CASE STUDY
HIGH TEMPERATURE PIPELINE REPAIR
Belzona Repairs Through-Wall Pipeline Defect
Industry: Oil & Gas
Application: High Temperature Pipe Repair
Products: Belzona 1511, Belzona 1983, Belzona 9381, Belzona 9382
Customer Location: VIC, Australia
Application Date: Dec 2020
PROBLEM
A high temperature, fuel oil pipeline developed a critical (Class 3) through wall defect.
The defect was calculated at 40 × 40 mm, with damage extending 90 mm in the axial direction. Operating at 90°C and 17.6 bar, the pipeline required an engineered repair solution capable of restoring containment and structural integrity under demanding service conditions.
Pipe with through-wall defect
APPLICATION
A repair solution comprising Belzona 1511 and the Belzona SuperWrap II Composite Repair System was selected as the preferred method for restoring the integrity of the pipeline.
Following surface preparation by grit blasting to achieve SA 2.5 cleanliness with a 75-micron surface profile, Belzona 1511 was applied directly to the critical defect area. This was used to fill, seal, and smooth the damaged section, creating a suitable profile for the composite wrap system.
The repair was then reinforced using Belzona SuperWrap II, applied in accordance with the engineered design. The system consisted of an 11-wrap composite repair over a total repair length of 540 mm, using Belzona 1983 resin. The completed repair was designed to restore containment and provide a further 10 years of service life under the pipeline’s operating conditions.
Defect pit filled with Belzona 1511
Belzona SuperWrap II application in progress
Belzona SuperWrap II application completed
OUTCOME
The Belzona SuperWrap II composite repair system was chosen as the preferred solution since it can be designed and applied in accordance with ISO 24817 and ASME PCC-2 standards. Belzona 1983 resin was chosen for its high heat resistance of up to 150°C, making it suitable for the pipeline’s elevated operating temperature.
The repair was designed in-house by our Belzona SuperWrap II designer and applied by trained, validated Belzona SuperWrap II applicators, ensuring a compliant installation and a reliable long-term repair.
More Information?
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Products
Belzona SuperWrap II
Composite repair system, Belzona SuperWrap II, offers a new generation repair solution for restoring the strength of holed, weakened and corroded pipe and tank walls. It is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application.
Belzona 1511 (Super HT-Metal)
A two-part repair composite based on a solvent-free epoxy resin reinforced silicon with steel alloy. This high temperature repair system is designed for metal repair and rebuilding equipment and provides excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150 °C (302 °F).
Frequently asked questions
How can a through-wall defect in a high-temperature fuel oil pipeline be repaired?
A through-wall defect in a high-temperature fuel oil pipeline can be repaired using an engineered composite repair system. In this case study, Rezitech used Belzona 1511 to fill, seal, and smooth the defect area before applying the Belzona SuperWrap II Composite Repair System to restore containment and structural integrity.
What products were used for this high-temperature pipeline repair?
The repair used Belzona 1511 and the Belzona SuperWrap II Composite Repair System, with Belzona 1983 resin used as part of the composite wrap. Belzona 1511 was applied to the defect area, while the SuperWrap II system provided the engineered reinforcement required for long-term pipeline integrity.
Why was Belzona SuperWrap II selected for the pipeline repair?
Belzona SuperWrap II was selected because it is an engineered composite repair system that can be designed and applied in accordance with ISO 24817 and ASME PCC-2 standards. This made it suitable for repairing a critical Class 3 through-wall defect on a pipeline operating at 90°C and 17.6 bar.
Can Belzona composite repairs be used on high-temperature pipelines?
Yes. Belzona composite repair systems can be used on high-temperature pipelines when the correct resin and engineered design are selected. For this repair, Belzona 1983 resin was chosen for its high heat resistance of up to 150°C, providing suitability for the pipeline’s 90°C operating temperature.
How long was the Belzona pipeline repair designed to last?
The completed Belzona SuperWrap II repair was designed to provide a further 10 years of service life under the pipeline’s operating conditions. The system consisted of an 11-wrap composite repair over a total repair length of 540 mm, applied by trained and validated applicators.
About Rezitech
Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power, water and waste water, pulp and paper, marine, manufacturing among others.
We value growth and innovation within the maintenance solutions industry
Our Mission
To provide industry with easier maintenance solutions that provide cost effective, efficient and long lasting results for our valued clients. To provide an integrated industry service by striving for Rezitech being a truly complete solutions provider!
Our Values
We value the needs of our clients and place a huge emphasis on providing specialist skills and knowledge.
From engineering to fitting, blasting or coating to sales, administration and customer service, we highly value our organisation and encourage diversity andgrowth to benefit our client and our team of people.
Our Vision
To strive for excellence in our delivery of high quality industrial maintenance solutions. To be our clients’ preferred choice when it comes to solving all of their maintenance and new pump needs while helping to reduce their carbon imprint.
Health and Safety
Rezitech is committed to ensuring the health, safety and welfare of its employees, contractors, visitors and customers who may be affected by Rezitech’s operations. We strive to pursue standards of safety that meet and exceed statutory duties.
Community & Environment
While providing solutions for our clients Rezitech focuses on identifying ways to improve business environmental performance while increasing productivity and reducing costs of production for the benefit our clients and hence the community.
The Future
To continue to strive for excellence! To continue to lead the way in industrial maintenance solutions and services and provide our clientele with high quality, complete and reliable products and services.
Rezitech’s mission is to make its liquid ring vacuum pump expertise available to sugar mills, paper mills and process industries worldwide. We currently export to:
- Fiji
- Thailand
- Mauritius
- Indonesia
- United Kingdom
- Phillipines
- Malaysia
- New Zealand
- Papua New Guinea
We are constantly on the look out for new export opportunities and new countries to export to Rezitech places an emphasis on the development of export business worldwide.
For further information on a Flowtech Distributorship please contact us.
