Technowrap™ Composite Repair – Air Buffer Bottle (FPSO)

Overview

Gecric Integrity, in collaboration with ICR Integrity, successfully restored the integrity of an air buffer bottle aboard an FPSO offshore Ghana. The asset had experienced significant wall loss due to external corrosion, with remaining thickness reduced to approximately 1.8mm. The client required a fast, reliable, and cost-effective repair solution with a 10-year design life—without shutting down operations.

Planning

• Joint engineering collaboration between Gecric Integrity and ICR Integrity
• Detailed assessment of corrosion severity and remaining wall thickness
• Selection of Technowrap™ composite repair system for high-temperature application
• Development of execution plan to ensure no shutdown and minimal operational disruption
• Mobilization of local Ghana-based technicians and materials

Execution

• Surface preparation to ST3 standard with minimum roughness of 54 microns
• Application of Technowrap™ 2K cloth with high-temperature resin
• Installation of 15 engineered composite layers
• Continuous quality assurance checks throughout the repair process
• Completion of installation across five-day shifts offshore

Operational Challenge

• Significant wall loss (down to 1.8mm thickness)
• Offshore FPSO constraints with limited access
• Requirement to execute repair without shutdown
• Need for a durable, long-term solution (10-year design life)

Outcome

• Successfully restored structural integrity of the air buffer bottle
• Achieved full 10-year design life requirement
• Completed repair safely with zero shutdown
• Delivered a fast, cost-effective solution minimizing production impact