Live Leak Seal on GRE Seawater Header Line


The repair had the following specifications:

Design Pressure 600kPa
Diameter (NB) 250mm
Surface Preparation ST3
Material of Line GRE (Glass Reinforced Epoxy)
Design Temperature 80 °C
Design Life 4 years
Defect Type Hole
Defect Size 5m Through Wall
Geometry Valve and I-Beam 
Crew Size 2
Consolidation Method Stricture



An offshore gas processing facility in Western Australia experienced localised internal erosion, resulting in a through-wall defect on the flanged interface of a GRE Seawater Header Line.
A live leak seal was installed with a flow diversion plate to ensure there was no loss of production through shutting down whist the engineered composite repair was applied.


  • Technowrap™ 2K glass fibre was used which enables existing inspection systems to continue to being used
  • Quick response with engineering completed and mobilization to site in a short timeframe
  • Flow diversion used to ensure a dry surface throughout the duration of the repair


  • Shutdown not required maintaining production on the facility
  • Valve handle remained operational
  • Spool did not require replacement

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